Board, method for manufacturing a board and a panel comprising such board material

Abstract

A board including a plurality of layers having a different composition. At least one of the layers is based on MgO and MgChloride and/or at least one of said layers is based on MgO and MgSulphate. Methods for manufacturing such boards, and methods for manufacturing coated panels include such board.

1 . A floor, wall or ceiling panel comprising a board and a decorative top layer; wherein the decorative top layer is provided on the board;
 wherein the board is based on MgO and MgChloride (a board of so called MOC or magnesiumoxychloride) or wherein the board is based on MgO and MgSulphate (a board of so-called MOS or magnesiumoxysulphate);   wherein the board is provided at at least two opposite edges with coupling parts allowing to couple two such panels at the respective edges, wherein a vertical locking perpendicular to the plane of coupled panels and/or a horizontal locking perpendicular to the respective edges and in the plane of the coupled panels is obtained;   wherein said board comprises at least one additive selected from the list metal soap, silanes, siloxanes and/or siliconates or a combination of both.   
     
     
         2 . The panel of  claim 1 , wherein at least one of said at least two opposite edges is treated with a sealant. 
     
     
         3 . The panel of  claim 2 , wherein the sealant is selected from the list of an alkali resistant sealant, paraffin, latex, acrylic, polyurethane, polyvinylalchohol (PVA), ethylene vinylacetate (EVA), PVAc dispersion, acylic styrene emulsion, silicate glue, solvent based one component resin, a solvent based two component resin, silane or siloxanes. 
     
     
         4 . The panel of  claim 1 , wherein the body of the board comprises a binder selected from the list of latex, acrylic resin, polyurethane, polyvinylalchohol (PVA), ethylene vinylacetate (EVA), polyvinyl acetate (PVAc), acrylic styrene resin, silicate glue, silane or siloxanes). 
     
     
         5 . The panel of  claim 1 , wherein the board comprises separate fibers, wherein the separate fibers are selected from the list of glass fibers, PVA fibers, cellulose fibers and wood fibers. 
     
     
         6 . The panel of  claim 1 , wherein said coupling parts are basically shaped as a tongue and a groove, wherein the groove is bordered by an upper and a lower lip, wherein said upper lip is at least partially provided in a layer of the board comprising cellulose fibers. 
     
     
         7 . The panel of  claim 6 , wherein said upper lip is at least partially provided in a layer of the board comprising a higher cellulose content than at a central layer of the board. 
     
     
         8 . The panel of  claim 1 , wherein the decorative top layer comprises a melamine treated paper sheet heat pressed to said board. 
     
     
         9 . The panel of  claim 1 , wherein the board comprises one or more than one of:
 a 517 MOS phase: 5Mg(OH)2·MgSO4·7H2O;   a 518 MOC phase: 5Mg(OH)2·MgCl2·8H2O;   a 318 MOC phase: 3Mg(OH)2·MgCl2·8H2O;   a 513 MOS phase: 5Mg(OH)2·MgSO4·3H2O; or   a 318 MOS phase: 3Mg(OH)2·MgSO4·3H2O.   
     
     
         10 . A floor, wall or ceiling panel comprising a board and a decorative top layer; wherein the decorative top layer is provided on the board;
 wherein the board is based on MgO and MgChloride (a board of so called MOC or magnesiumoxychloride) or wherein the board is based on MgO and MgSulphate (a board of so-called MOS or magnesiumoxysulphate);   wherein the board is provided at at least two opposite edges with coupling means allowing to couple two such panels at the respective edges, wherein a vertical locking perpendicular to the plane of coupled panels and/or a horizontal locking perpendicular to the respective edges and in the plane of the coupled panels is obtained;   wherein at least one of said at least two opposite edges is treated with a sealant.   
     
     
         11 . The panel of  claim 10 , wherein the sealant is selected from the list of an alkali resistant sealant, paraffin, latex, acrylic, polyurethane, polyvinylalchohol (PVA), ethylene vinylacetate (EVA), PVAc dispersion, acylic styrene emulsion, silicate glue, solvent based one component resin, a solvent based two component resin, silane or siloxanes. 
     
     
         12 . The panel of  claim 10 , wherein said board comprises at least one additive selected from the list metal soap, silanes, siloxanes and/or siliconates or a combination of both. 
     
     
         13 . The panel of  claim 10 , wherein the body of the board comprises a binder selected from the list of latex, acrylic resin, polyurethane, polyvinylalchohol (PVA), ethylene vinylacetate (EVA), polyvinyl acetate (PVAc), acrylic styrene resin, silicate glue, silane or siloxanes). 
     
     
         14 . The panel of  claim 10 , wherein the board comprises separate fibers, wherein the separate fibers are selected from the list of glass fibers, PVA fibers, cellulose fibers and wood fibers. 
     
     
         15 . The panel of  claim 10 , wherein said coupling parts are basically shaped as a tongue and a groove, wherein the groove is bordered by an upper and a lower lip, wherein said upper lip is at least partially provided in a layer of the board comprising cellulose fibers. 
     
     
         16 . The panel of  claim 15 , wherein said upper lip is at least partially provided in a layer of the board comprising a higher cellulose content than at a central layer of the board. 
     
     
         17 . The panel of  claim 10 , wherein the decorative top layer comprises a melamine treated paper sheet heat pressed to said board. 
     
     
         18 . The panel of  claim 10 , wherein the board comprises one or more than one of:
 a 517 MOS phase: 5Mg(OH)2·MgSO4·7H2O;   a 518 MOC phase: 5Mg(OH)2·MgCl2·8H2O;   a 318 MOC phase: 3Mg(OH)2·MgCl2·8H2O;   a 513 MOS phase: 5Mg(OH)2·MgSO4·3H2O; or   a 318 MOS phase: 3Mg(OH)2·MgSO4·3H2O.